Isuzu Trooper (2000 year). Manual — part 139
TRANSFER CASE (STANDARD TYPE)
4D1–33
E07RW010
4D1–34 TRANSFER CASE (STANDARD TYPE)
Special Tools
ILLUSTRATION
PART NO.
PART NAME
J–22912–01
Bearing
remover/installer
J–38592
Transfer case oil seal
installer
J–37219
Mainshaft nut wrench
J–37223
Rear output shaft and
bearing installer
J–39209
Punch, end nut
ILLUSTRATION
PART NO.
PART NAME
J–38594
Front output shaft oil
seal installer
J–39208
Rear oil seal installer
J–37486–A
Bearing installer adapter
J–8614–11
Flange holder
J–37217
Mainshaft end bearing
remover
TRANSFER CASE (STANDARD TYPE)
4D1–35
ILLUSTRATION
PART NO.
PART NAME
J–37487
Puller
J–8092
Driver handle
4D2–1
TRANSFER CASE (TOD)
TROOPER
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution
4D2–1
. . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly
4D2–2
. . . . . . . . . . . . . . . . .
Removal
4D2–2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
4D2–3
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal
4D2–5
. . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal and Associated
Parts
4D2–5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
4D2–5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
4D2–5
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD ECU
4D2–7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
4D2–7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
4D2–7
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair
4D2–8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection
4D2–8
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case
4D2–9
. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View
4D2–9
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–9
. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–10
. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Cover Assembly
4D2–12
. . . . . . . . . . . . . . . .
Disassembled View
4D2–12
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–12
. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–14
. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly Clutch Pack and
Clutch Cam
4D2–16
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View
4D2–16
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–16
. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock
4D2–18
. . . . . . . . . . . .
Disassembled View
4D2–18
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–18
. . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft
4D2–20
. . . . . .
Disassembled View
4D2–20
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–21
. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case
4D2–23
. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View
4D2–23
. . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–24
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
4D2–26
. . . . . . . . . . . . . . . . . .
Transfer Case
4D2–30
. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View
4D2–30
. . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–30
. . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft
4D2–33
. . . . . .
Disassembled View
4D2–33
. . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–33
. . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock
4D2–36
. . . . . . . . . . . .
Disassembled View
4D2–36
. . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–36
. . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pack and Clutch Cam
4D2–38
. . . . . . . . . . . . .
Disassembled View
4D2–38
. . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–38
. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications
4D2–40
. . . . . . . . . . . . .
Special Tools
4D2–42
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
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